Catalytic Cracking Reactor for Low-Emission Hydrogen and Solid Carbon
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Solution Overview
Problem
Current technologies for catalytic cracking of light hydrocarbons, such as steam methane reforming with or without carbon capture sequestration, produce high carbon emissions and are inefficient in producing high purity hydrogen and solid carbon, while reactor design and engineering difficulties hinder cost-effective processes.
Innovation Solution
A reactor system and process that utilizes a carbon supported metal catalyst to crack light hydrocarbons, incorporating a product effluent separation system to remove solid carbon and gaseous impurities, an acid leaching system to purify solid carbon, and a catalyst synthesis system to regenerate catalysts, ensuring optimal temperature and high purity products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If steam methane reforming with carbon capture sequestration is used, then high purity hydrogen can be produced, but carbon emissions are significantly high and production cost is increased
Solution Approach 1:
The patent changes the fundamental reaction parameters by using catalytic cracking instead of steam reforming, operating at temperatures of 700-900°C with light hydrocarbon feedstock to directly produce hydrogen and solid carbon, avoiding the high carbon emissions associated with conventional steam methane reforming and carbon capture sequestration processes
Solution Approach 2:
The patent extracts and removes solid carbon deposits from the reaction system through a separation unit, preventing carbon buildup that would otherwise require capture and sequestration, while the produced hydrogen is separated and purified to achieve high purity without the need for carbon capture infrastructure
2Object-generated harmful factors
If catalytic cracking is used to produce hydrogen and solid carbon, then carbon emissions are reduced, but reactor design complexity and engineering difficulties increase
Solution Approach 1:
The patent divides the complex catalytic cracking process into distinct functional modules: a reactor for catalytic cracking, a separation unit for removing solid carbon and separating gas streams, and a purification unit for hydrogen purification. This segmentation simplifies the overall reactor design and engineering implementation by making each component's function clear and manageable
Solution Approach 2:
The patent introduces a carbon supported metal catalyst as an intermediary substance that facilitates the catalytic cracking reaction, enabling the conversion of light hydrocarbons to hydrogen and solid carbon at lower temperatures and with higher efficiency, thereby reducing the engineering complexity associated with high-temperature thermal cracking
3Device complexity
If conventional separation methods are used without catalyst regeneration, then process simplicity is maintained, but production cost increases and sustainability decreases
Solution Approach 1:
The patent implements a catalyst regeneration system where spent carbon supported metal catalyst is regenerated by burning off accumulated carbon deposits and reimpregnating with fresh metal catalyst. This recovery process extends catalyst life and maintains high hydrogen production efficiency, reducing production costs and improving sustainability without significantly increasing process complexity
Solution Approach 2:
The patent establishes continuous operation of the catalytic cracking process by implementing online catalyst regeneration, where spent catalyst is continuously regenerated and returned to the reactor. This ensures uninterrupted hydrogen production and maintains optimal catalyst activity, improving productivity and reducing production costs compared to batch processes requiring shutdowns
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Produces high purity hydrogen and solid carbon with significantly lower carbon emissions by maintaining an optimized temperature profile, recycling unreacted hydrocarbons, and regenerating catalysts, thereby achieving cost-effective and efficient production.
Implementation Method 1
catalytically cracking a light hydrocarbon feedstock in the presence of a carbon supported metal catalyst comprising one or more active metal compounds
Implementation Method 2
separating a gas stream comprising hydrogen and unreacted light hydrocarbons from a product effluent
Implementation Method 3
an acid leaching system to purify solid carbon
Implementation Method 4
maintaining an optimized temperature profile
Data Source
AI summary
A process for producing high purity hydrogen includes separating a gas stream comprising hydrogen and unreacted light hydrocarbons from a product effluent comprising the gas stream comprising the hydrogen and the unreacted light hydrocarbons, and a spent carbon supported metal catalyst comprising one or more active metal compounds and solid carbon deposits derived from catalytically cracking a light hydrocarbon feedstock in the presence of a carbon supported metal catalyst comprising one or more active metal compounds in a reactor, separating the hydrogen and the unreacted light hydrocarbons from the gas stream comprising the hydrogen and the unreacted light hydrocarbons, and withdrawing high purity hydrogen.